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  1. #1
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    Default Repairing floor rust

    Well, I gone and done it. Taking on the floor rust before I move on to replacing my rotted rockers for something thicker. But I thought I would separate the threads so anyone wanting see the rocker mod in the future wouldn't have to wade through the floor stuff.

    The unsuspecting, and pretty filthy (will ask for tips on that later) carpet hides way too much. Being my jeep lived in iowa before i got it I knew i'm in for some work but between the carpet and undercoating I didn't really know what to expect.

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    More to getting the carpet out than I thought but it went smoothly.

  2. #2
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    Default Re: Repairing floor rust

    Once the carpet was out the damage was apparent. But not too bad, since the rockers are about 50% either gone or near flying off.


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    I wanted a better look so I took a wire wheel to the worst spots and opened up a few more...

    Front Passenger

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    Rear Passenger

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    Front Driver

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    And quite a shock the rear driver pan was perfect, like show room immaculate. Especially since the worst spot on the rockers are attached to it.

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  3. #3
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    Default Re: Repairing floor rust

    Mostly anything that ate through got cut out. The others are small and I am hoping to fill them. Hopes aren't high for that though. 12 new floor vents... and one for a heater.

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    I do realize this isn't the best way to go about this, but I can in no way afford new floor pans so this will get me by for a few more years.
    Last edited by XJ Wheeler; 12-07-2015 at 03:40 AM.

  4. #4
    abebehrmann's Avatar
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    Default Re: Repairing floor rust

    Quote Originally Posted by XJ Wheeler View Post
    . 12 new floor vents... and one for a heater.
    Those are speed holes, they make the Jeep go faster.

    For maximum heating ability, drill some holes in the muffler to allow for thermal expansion.

    Good work Jake, can't wait to see the finished product!

  5. #5
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    Default Re: Repairing floor rust

    I think you will be just fine doing it like this. You don't have all that much rust to deal with
    230 hp 4.3L Chevy
    Built 4L60E with manual lockout
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    7.5" RE front and bastard pack rear on custom long arms
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    And a bunch of other stuff

  6. #6
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    Default Re: Repairing floor rust

    Agreed. Looking good so far Jake. I cringe when I think about what's under the carpet of mine. Keep us updated with pics and good luck!

  7. #7
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    Default Re: Repairing floor rust

    Quote Originally Posted by abebehrmann View Post
    Those are speed holes, they make the Jeep go faster.

    For maximum heating ability, drill some holes in the muffler to allow for thermal expansion.

    Good work Jake, can't wait to see the finished product!
    Lol, I could use a bit more top end.
    Quote Originally Posted by 4.3LXJ View Post
    I think you will be just fine doing it like this. You don't have all that much rust to deal with
    Thanks, Steve. I was surprised it wasn't worse. Will definitely be glad to have this taken care of finally.

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  8. #8
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    Default Re: Repairing floor rust

    Quote Originally Posted by xj-jake View Post
    Agreed. Looking good so far Jake. I cringe when I think about what's under the carpet of mine. Keep us updated with pics and good luck!
    Thanks Jake! Exactly how I felt about mine for years. I also want to clean up under the floor to check and seal both sides but I don't have a sand blaster and it would take way to long with a grinder. Hmmm, Christmas is coming up...

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  9. #9
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    Default Re: Repairing floor rust

    I got the patch panels fabbed up. Really wanted to get them tacked in but I ran out of time. Just pics of the more complicated ones. I tell you guys, the HF body hammer set came in very handy.

    Drivers side

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  10. #10
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    Default Re: Repairing floor rust

    Passenger

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  11. #11
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    Default Re: Repairing floor rust

    Nice work Jake. You might want to lay a strip of metal under the seam. It will make the welding so much easier
    230 hp 4.3L Chevy
    Built 4L60E with manual lockout
    Atlas 4 speed
    Griffin radiator
    On board air
    Warn 9.5ti on custom bumper
    7.5" RE front and bastard pack rear on custom long arms
    30 gal gas tank
    lockers
    And a bunch of other stuff

  12. #12
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    Default Re: Repairing floor rust

    Quote Originally Posted by 4.3LXJ View Post
    Nice work Jake. You might want to lay a strip of metal under the seam. It will make the welding so much easier
    Oh, I like the sound of that! To keep a puddle forming and not burning through? I've got a piece of aluminum flat bar. Its pretty thin but you think will that work?

  13. #13
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    Default Re: Repairing floor rust

    Yes the aluminum will work just fine Jake. We used to use chunks of aluminum for backers when I worked at the trailer building place. The advantage to aluminum is the puddle won't stick to I and you'll be able to remove it easily. The only down side is that the back side of the weld (the side against the aluminum) may look a little different. Hit it with a wire wheel or flap disk and you should be fine.

  14. #14
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    Default Re: Repairing floor rust

    Quote Originally Posted by xj-jake View Post
    Yes the aluminum will work just fine Jake. We used to use chunks of aluminum for backers when I worked at the trailer building place. The advantage to aluminum is the puddle won't stick to I and you'll be able to remove it easily. The only down side is that the back side of the weld (the side against the aluminum) may look a little different. Hit it with a wire wheel or flap disk and you should be fine.
    Cool! I've wanted to pick up a welding spoon for a while. It's not much at HF, just haven't "needed" it.

    Thanks to you both. Let you know how it goes.

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  15. #15
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    Default Re: Repairing floor rust

    Looks great bro! And props on pulling the rug and doing it right. Patches look perfect. Good idea on backing the seams too. Alum makes even more sense

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